Daytripper Chair This chair is made up of two interlocking pieces that can be taken apart for easy storage or transport. When set up, the chair is sturdy, comfortable, and bears a simple elegance. You can break it down and easily carry it to the beach or a little league game. Or keep a couple on hand in storage for when you need extra outdoor seating. BUILD TIME Cutting parts: 2 3 hours Assembly: 2 hours Finishing: 2 hours Total: 6 7 hours 1
Daytripper Chair TOOLS Miter saw or circular saw Table saw Drill/driver 1/8" drill bit Jig saw Damp rag to wipe up excess glue SUPPLIES A B X 2 X 2 (2) 2 x 6 x 8' (2) 1 x 6 x 8' 1/8" x 24" x 48" hardboard for templates 2" deck screws Waterproof wood glue CUT LIST C X 1 A (2) 1 ½ x 5 ½ x 36" B (2) 1 ½ x 5 x 34" C (1) ¾ x 3 ½ x 23" D (2) ¾ x 2 ½ x 23" E (11) ¾ x 2 x 23" D X 2 E X 11 2
Daytripper Chair Back leg detail ½" radius on all corners 2 ¾" A 2 ¾" 5 ½" 2 ¾" 18" 36" Seat leg detail 2 ½" B 2 ½" 5" 2 ½" 17" 34" Exploded view C E E ½" spaces between all slats B 20" B D A A D 23" 12 ½" 18 ¾" Top slat detail 23" 9" 9" 1¾" Two 1" diameter holes joined w/ jig saw 3
Daytripper Chair BUILDING STEPS 01 Cut your 2 x stock to length for the back legs (A) and seat legs (B), then lay out the curves according to the dimensions on the illustration detail (see special instructions for laying out curves). To round the corners of your legs, lay a 25-cent piece in each corner and trace it to achieve what amounts to a ½" radius. You may find it easier to first lay out the curves on a piece of hardboard and make a pattern. This will ensure consistent pieces and you ll have the pattern for later use if you decide to build more chairs. 02 Cut the top slat (C), seat supports (D) and slats (E) to dimensions on the cut list. On your top slat (C), mark two points 9" in from each end and centered 1 ¾" from the top and bottom edges, drill two 1" diameter holes at those points. Connect the outside edges of those two holes with a straightedge and cut those lines with a jig saw to create a hand-grip hole. 03 Begin assembly by attaching the seat supports (D) to the back legs (A) according to the dimensions in the illustration. You may have to use a framing square to make sure the supports are square on the legs. 04 Start attaching slats by beginning with the top slat (C) flush with the top edges of the back legs (A). Use ½" spacers to continue attaching 5 more slats (E). Make sure all slats are evenly spaced and square to the legs. 05 Attach the remaining six slats (E) to the seat legs (B), beginning with the front slat flush to front edges of the legs. Again, use ½" spacers and keep slats square to the legs. 4
Daytripper Chair BUILDING STEPS 06 Sand all edges and surfaces smooth, apply a waterproofing finish according to manufacturer directions, interlock the two components and relax! TIP: This is one of those projects that may be more easily sanded and finished without all the pieces connected. If you choose this method, do an initial assembly without glue to make sure all pilot holes and edges line up and appear to your liking. Then disassemble, sand smooth, and reassemble with glue and screws. 5
Daytripper Chair LAYING OUT CURVES 00 When you need to lay out curved lines, there are many different methods you may use. The following technique is one of the easiest and requires only that you know the piece s final length and width, as well as a piece of hardboard or other pliable material that can easily be pushed or pulled to create a consistent curved line. This illustration uses the curved legs from the daytripper chair as an example, but you can use the concepts for any of the projects featured in this section. 01 After cutting your raw stock to length, measure up from the bottom edge on both ends and mark the width of the piece (2 ¾" in this example). Then, measure down from the top edge along the centerline and mark the same measurement. 02 Drive finish nails into your assembly table at each end at the bottom corners of your stock, place your piece of hardboard against those nails and push up along the centerline until the edge of your hardboard touches your mark at the centerline (you may have to push and bend the nails to make sure your hardboard edge intersects the bottom corners properly). Hold the hardboard steady and lightly trace along the edge to get your curve. 03 Tack two more nails into the assembly table at the 2 ¾" marks along the edge of both ends and place your hardboard against them. Push along the centerline until the edge of the hardboard touches the top edge of the stock and trace that curved line. 04 Your result is two parallel and consistent curves exactly 2 ¾" apart from each other along the entire length of the stock. Make your cut with a jig saw or band saw, leaving the line on your finished piece, and then sand cuts smooth until you just remove the pencil line. 6
FASTENER AND HARDWARE INFORMATION SHEET For interior or exterior applications Use fasteners and hardware that are in compliance with the manufacturer s recommendations and the building codes for their intended use. As with any good design and construction practices, treated wood should not be used in applications where trapped moisture or water can occur. Where design and/or actual conditions allow for constant, repetitive or long periods of wet conditions, only stainless steel fasteners should be used. For exterior applications The following minimum galvanization levels may be used for connectors, joist hangers, fasteners and other hardware that are placed in direct contact with exterior applications of micronized copper treated wood: Fasteners - nails, screws, etc. ASTM A 153 (1 oz/ft²) Hardware - connectors, joist hangers, etc. ASTM A 653 G90 (0.90 oz/ft²) The effects of other building materials within a given assembly, along with environmental factors, should also be considered when selecting the appropriate hardware and fasteners to use for a given project containing treated wood. Stainless Steel fasteners and hardware are required for Permanent Wood Foundations below grade and are recommended for use with treated wood in other severe exterior applications such as swimming pools, salt water exposure, etc. - Type 304 and 316 are recommended grades to use. Aluminum building products may be placed in direct contact with YellaWood brand products used for interior uses and above ground exterior applications such as decks, fencing, and landscaping projects. Examples of aluminum products include siding, roofing, gutters, door and window trim, flashing, nails, fasteners and other hardware connectors. However, direct contact of treated products and aluminum building products should be limited to code-compliant construction applications that provide proper water drainage and do not allow the wood to be exposed to standing water or water immersion. We recommend you contact the aluminum building products manufacturer for its recommendations regarding use of its aluminum products in contact with treated wood in ground contact applications or when exposed to salt water, brackish water, or chlorinated water, such as swimming pools or hot tubs. Also check with the aluminum building products manufacturer regarding compatibility with other chemicals and cleaning agents and the use of their aluminum products in commercial, industrial, and specialty applications such as boat construction. YellaWood brand pressure treated products are treated with copper and other preservatives (the Preservatives ) and preservative methods, systems, and technologies of unrelated third parties. For details regarding the Preservatives, methods, systems, and technologies used by Great Southern Wood Preserving, Incorporated, see http://www.greatsouthernwood.com/products/ yellawood or write us at P.O. Box 610, Abbeville, AL 36310. Ask dealer for warranty details or visit http://www.greatsouthernwood.com/products/ warranties. For important handling and other information concerning our products or for a copy of the YellaWood brand Material Safety Data Sheet (MSDS), please visit us at www.greatsouthernwood.com or write us at P.O. Box 610, Abbeville, AL 36310. YellaWood and the yellow tag are federally registered trademarks of Great Southern Wood Preserving, Incorporated. Great Southern Wood Preserving, Incorporated makes no warranties expressed or implied as to the fitness for a particular purpose of this plan. 7
IMPORTANT INFORMATION Consult the end tag to determine which preservative or preservative system was used in the treatment of that particular product. YellaWood brand products may be used in direct contact with aluminum building products when limited to code-compliant construction applications that provide proper water drainage and do not allow the wood to be exposed to standing water or water immersion. Use fasteners and other hardware that are in compliance with building codes for the intended use. Do not burn preserved wood. Wear a dust mask and goggles when cutting or sanding wood. Wear gloves when working with wood. Some preservative may migrate from the treated wood into soil/water or may dislodge from the treated wood surface upon contact with skin. Wash exposed skin areas thoroughly. All sawdust and construction debris should be cleaned up and disposed of after construction. Wash work clothes separately from other household clothing before reuse. Preserved wood should not be used where it may come into direct or indirect contact with drinking water, except for uses involving incidental contact such as fresh water docks and bridges. Do not use preserved wood under circumstances when the preservative may become a component of food, animal feed or beehives. Do not use preserved wood as mulch. Only preserved wood that is visibly clean and free of surface residue should be used. If the wood is to be used in an interior application and becomes wet during construction, it should be allowed to dry before being covered or enclosed. If you desire to apply a paint, stain, clear water repellent or other finish to your preservativetreated wood, we recommend following the manufacturer s instructions and label of the finishing product. Before you start, we recommend you apply the finishing product to a small exposed test area before finishing the entire project to ensure it provides the intended result before proceeding. Mold growth can and does occur on the surface of many products, including untreated and treated wood, during prolonged surface exposure to excessive moisture conditions. To remove mold from the treated wood surface, wood should be allowed to dry. Typically, mild soap and water can be used to remove remaining surface mold. For more information visit www.epa.gov Projects should be designed and installed in accordance with federal, state and local building codes and ordinances governing construction in your area, and in accordance with the National Design Specifications (NDS) and the Wood Handbook. Disposal Recommendations: Preserved wood may be disposed of in landfills or burned in commercial or industrial incinerators or boilers in accordance with federal, state and local regulations. 8